US10501598B2 - Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material - Google Patents

Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material Download PDF

Info

Publication number
US10501598B2
US10501598B2 US15/637,723 US201715637723A US10501598B2 US 10501598 B2 US10501598 B2 US 10501598B2 US 201715637723 A US201715637723 A US 201715637723A US 10501598 B2 US10501598 B2 US 10501598B2
Authority
US
United States
Prior art keywords
layer
foam
recycled
polypropylene
polyethylene
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active, expires
Application number
US15/637,723
Other languages
English (en)
Other versions
US20190002662A1 (en
Inventor
Jesse Jude BALDWIN
Dan Ben-Daat
Winston Kenneth BISHOP, III
Kaitlyn Michelle BOCK
Pawel Sieradzki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Plastics America Inc
Original Assignee
Toray Plastics America Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toray Plastics America Inc filed Critical Toray Plastics America Inc
Priority to US15/637,723 priority Critical patent/US10501598B2/en
Priority to MX2018008082A priority patent/MX2018008082A/es
Priority to CN201810692634.6A priority patent/CN109203340A/zh
Priority to ES18180821T priority patent/ES2911007T3/es
Priority to KR1020180075424A priority patent/KR102615688B1/ko
Priority to EP18180821.3A priority patent/EP3421213B1/en
Priority to JP2018124382A priority patent/JP7280669B2/ja
Publication of US20190002662A1 publication Critical patent/US20190002662A1/en
Assigned to TORAY PLASTICS (AMERICA), INC. reassignment TORAY PLASTICS (AMERICA), INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEN-DAAT, DAN, BOCK, KAITLYN MICHELLE, BALDWIN, Jesse Jude, BISHOP, WINSTON KENNETH, III, SIERADZKI, PAWEL
Application granted granted Critical
Publication of US10501598B2 publication Critical patent/US10501598B2/en
Active legal-status Critical Current
Adjusted expiration legal-status Critical

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/35—Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C08J9/10—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing nitrogen, the blowing agent being a compound containing a nitrogen-to-nitrogen bond
    • C08J9/102—Azo-compounds
    • C08J9/103—Azodicarbonamide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/24—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F10/02—Ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F10/04—Monomers containing three or four carbon atoms
    • C08F10/06—Propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
    • B29C35/045—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using gas or flames
    • B29C2035/046—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using gas or flames dried air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0855—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using microwave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • B29C2035/0872—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation using ion-radiation, e.g. alpha-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3488—Vulcanizing the material before foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
    • B29C44/505—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying extruding the compound through a flat die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26—Scrap or recycled material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/04—N2 releasing, ex azodicarbonamide or nitroso compound
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04—Homopolymers or copolymers of ethene
    • C08J2323/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10—Homopolymers or copolymers of propene
    • C08J2323/12—Polypropene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/33—Agglomerating foam fragments, e.g. waste foam
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • This disclosure relates to multilayer polyolefin foam structures. More particularly, this disclosure relates to coextruded, crosslinked polyolefin multilayer foam structures that include recycled polyolefin foam material.
  • FIGS. 1A and 1B An example of undesirable surface characteristics is illustrated in FIGS. 1A and 1B .
  • the foams in FIGS. 1A and 1B contain 8% parts per hundred parts resin (“PPHR”) shredded factory scrap crosslinked polypropylene/polyethylene blended foam.
  • PPHR parts per hundred parts resin
  • dark spots and “gels” can be seen as black colored recycled foam that has not been fully broken down, dispersed, and otherwise reincorporated into these foam sheets.
  • These spots and “gels” can cause problems for a laminator attaching a film, fabric, fiber layer, or leather to these foams.
  • adhesion at the “gel” may be poorer and may delaminate during a secondary operation such as thermoforming, causing a visible blister-like defect on the film, fabric, fiber layer, or leather.
  • Applicants have discovered methods for producing coextruded multilayer foam structures including a surface foam layer(s) derived from virgin (non-recycled) polyolefin material and an interior foam layer(s) derived from one or more recycled crosslinked polyolefin foam materials.
  • these foam structures can include the recycled foam layer(s) sandwiched or buried between two non-recycled foam layers. Accordingly, these multilayer foam structures can allow manufacturers to continue to use recycled crosslinked polyolefin foam material to create lower cost and more environmentally friendly products that can perform to the same standards as foam structures made entirely from non-recycled material.
  • a “structure” includes, but is not limited to, layers, films, webs, sheets, or other similar structures.
  • Some embodiments include methods of forming a multilayer structure that includes shredding a polyolefin foam, agglomerating the shredded foam, granulating the agglomerated foam to form a recycled, crosslinked polyolefin foam material; and coextruding a first layer and a second layer on a side of the first layer.
  • the first layer includes polypropylene, polyethylene, or a combination of polypropylene and polyethylene and a first chemical foaming agent and the second layer includes 2.5-25 wt % the recycled, crosslinked polyolefin foam material, 75-97.5 wt % polypropylene, polyethylene, or a combination of polypropylene and polyethylene, and a second chemical foaming agent.
  • the granules of the recycled, crosslinked polyolefin foam material have a width of 3-7 mm. In some embodiments, the granules of the recycled, crosslinked polyolefin foam material are mechanically pulverized, wherein particles of the mechanically pulverized recycled, crosslinked polyolefin foam material have a width of 0.2-2 mm. In some embodiments, the method can include coextruding a third layer on a side of the second layer opposite the first layer, wherein the third layer includes polypropylene and/or polyethylene and a third chemical foaming agent. In some embodiments, the first layer and the third layer are substantially free of recycled polyolefin material.
  • the first layer comprises polypropylene with a melt flow index of 0.1-25 grams per 10 minutes at 230° C. In some embodiments, the first layer comprises polyethylene with a melt flow index of 0.1-25 grams per 10 minutes at 190° C. In some embodiments, the first, second, and third layers comprise a crosslinking agent. In some embodiments, the first, second, and third chemical foaming agent is azodicarbonamide. In some embodiments, the first layer and third layer comprise polypropylene and polyethylene.
  • the method can include irradiating the coextruded layers with ionizing radiation and foaming the irradiated, coextruded layers.
  • the ionizing radiation is selected from the group consisting of alpha, beta (electron), x-ray, gamma, and neutron.
  • the coextruded structure is irradiated up to 4 separate times.
  • the ionizing radiation is an electron beam with an acceleration voltage of 200-1500 kV.
  • an absorbed electron beam dosage is 10-500 kGy.
  • the ionizing radiation crosslinks the extruded structure to a crosslinking degree of 20-75%.
  • foaming comprises heating the irradiated structure with molten salt.
  • the multilayer foam structure has a density of 20-250 kg/m 3 .
  • the multilayer foam structure has an average closed cell size of 0.05-1.0 mm.
  • the multilayer foam structure has a thickness of 0.2-50 mm.
  • a mean surface roughness for the first layer is less than 80 ⁇ m.
  • Some embodiments include a laminate that includes a multilayer foam structure and a laminate layer.
  • the multilayer foam structure can include a coextruded first foam layer that includes polypropylene and/or polyethylene and a second coextruded foam layer on a side of the first foam layer.
  • the second foam layer can include 2.5-25 wt. % the recycled, crosslinked polyolefin foam material and 75-97.5 wt. % polypropylene, polyethylene, or a combination of polypropylene and polyethylene.
  • the laminate layer can be on a side of the first foam layer opposite the second foam layer.
  • the laminate layer can be a film, fabric, fiber layer, or a leather.
  • the first foam layer can have a mean surface roughness less than 80 ⁇ m.
  • the recycled, crosslinked polyolefin foam material can include mechanically agglomerated or mechanically pulverized polyolefin foam material.
  • the multilayer foam structure can also include a coextruded third foam layer on a side of the second foam layer opposite the first foam layer.
  • the third layer can include polypropylene and/or polyethylene.
  • the first and/or third layers can be substantially free of recycled crosslinked polyolefin foam material.
  • the laminate can further be thermoformed onto a substrate such that the substrate is on a side of the third foam layer opposite the second foam layer.
  • references to “about” a value or parameter herein includes (and describes) variations that are directed to that value or parameter per se. For example, description referring to “about X” includes description of “X”.
  • reference to phrases “less than”, “greater than”, “at most”, “at least”, “less than or equal to”, “greater than or equal to”, or other similar phrases followed by a string of values or parameters is meant to apply the phrase to each value or parameter in the string of values or parameters.
  • a statement that the layer has less than about 20 wt %, about 15 wt %, or about 10 wt % of a chemical foaming agent is meant to mean that the weight percentage of the chemical foaming agent in the layer can be less than about 20 wt %, less than about 15 wt %, or less than about 10 wt %.
  • aspects and embodiments described herein include “consisting” and/or “consisting essentially of” aspects and embodiments.
  • the methods, systems, compositions, and devices can either comprise the listed components or steps, or can “consist of” or “consist essentially of” the listed components or steps.
  • system, composition, or device When a system, composition, or device is described as “consisting essentially of” the listed components, the system, composition, or device contains the components listed, and may contain other components which do not substantially affect the performance of the system, composition, or device, but either do not contain any other components which substantially affect the performance of the system, composition, or device other than those components expressly listed; or do not contain a sufficient concentration or amount of the extra components to substantially affect the performance of the system, composition, or device.
  • a method is described as “consisting essentially of” the listed steps, the method contains the steps listed, and may contain other steps that do not substantially affect the outcome of the method, but the method does not contain any other steps which substantially affect the outcome of the method other than those steps expressly listed.
  • substantially free of a specific component, a specific composition, a specific compound, or a specific ingredient in various embodiments is meant that less than about 2%, less than about 1%, less than about 0.5%, less than about 0.1%, less than about 0.05%, less than about 0.025%, or less than about 0.01% of the specific component, the specific composition, the specific compound, or the specific ingredient is present by weight.
  • “substantially free of” a specific component, a specific composition, a specific compound, or a specific ingredient indicates that less than about 1% of the specific component, the specific composition, the specific compound, or the specific ingredient is present by weight.
  • FIG. 1A is a first photo of a foam containing shredded recycled, crosslinked polyolefin foam.
  • FIG. 1B is a second photo of a foam containing shredded recycled, crosslinked polyolefin foam.
  • FIG. 2 is a photograph of mechanically pulverized, recycled crosslinked polyolefin foam used in producing Example 1.
  • FIG. 3 is a photograph of the granulated 3-7 mm wide agglomerates used in producing the masterbatch which was then used to produce the multilayered foam structures of Example 2 and 3.
  • FIG. 4 is a photograph of the unfoamed sheet of Example 1 at 30 ⁇ magnification and 45 degrees from the primary surface.
  • FIG. 5 is a photograph of the radiant heat foamed surface of Example 1 at 30 ⁇ magnification and 45 degrees from primary surface.
  • FIG. 6 is a photograph of the salt heated foam surface of Example 1 at 30 ⁇ magnification and 45 degrees from primary surface.
  • FIG. 7 is a photograph of the unfoamed sheet from surface B of Example 2 at 30 ⁇ magnification and 45 degrees from the primary surface.
  • FIG. 8 is a photograph of the unfoamed sheet from surface A of Example 2 at 30 ⁇ magnification and 45 degrees from the primary surface.
  • FIG. 9 is a photograph of the unfoamed sheet from surface B of Example 3 at 30 ⁇ magnification and 45 degrees from the primary surface.
  • FIG. 10 is a photograph of the unfoamed sheet from surface A of Example 3 at 30 ⁇ magnification and 45 degrees from the primary surface.
  • FIG. 11 is a flow chart illustrating the differences between the steps of preparing the recycled foam in U.S. Pat. No. 9,669,600 and the Examples of the present disclosure.
  • a layer or layers of the multilayered foam structure can be derived from recycled crosslinked polyolefin foam material.
  • the methods for producing a crosslinked, closed cell co-extruded multi-layer foam structure may include the steps of (a) co-extrusion, (b) irradiation, and (c) foaming.
  • Co-extrusion is the extrusion of multiple layers of material simultaneously.
  • This type of extrusion can utilize two or more extruders to deliver a steady volumetric throughput of material to an extrusion head (die) which can extrude the materials in the desired form.
  • compositions can be fed into multiple extruders to form an unfoamed, multilayer structure.
  • an “A” recycled foam composition can be fed into one extruder and a “B” nonrecycled foam composition can be fed into a second extruder.
  • the method of feeding ingredients into the extruders can be based on the design of the extruder and the material handling equipment available.
  • Blending ingredients of the compositions may be performed prior to feeding into the extruders, if necessary, to facilitate their dispersal.
  • a Henshel mixer can be used for such blending. All ingredients can be blended and fed thru a single port in an extruder. The ingredients can also be individually fed thru separate designated ports for each ingredient.
  • the crosslinking promoter or any other additive is a liquid, the promoter and/or additives can be added through a feeding gate (or gates) on the extruder or through a vent opening on the extruder (if equipped with a vent) instead of being blended with solid ingredients.
  • Combinations of blended ingredients and individual ingredient port feeding can also be employed.
  • Each extruder can deliver a steady amount of each composition into one or more manifolds followed by a sheeting die to create an unfoamed, co-extruded multilayer sheet.
  • feed block manifolds There are two common methods for co-extruding materials: (1) feed block manifolds; and (2) multi-manifolds within the die.
  • Elements of a feed block manifold can include: (a) inlet ports for upper, middle, and lower layers; (b) a streamlined melt lamination area that channels separate flow streams into one laminated melt stream inside the feed block; (c) an adapter plate between the feed block and the sheet die; and/or (d) a sheet die (similar to a monolayer die), wherein the laminated melt stream enters the center of the die and spreads out along the manifold flowing out of the die exit as a distinct multilayer extrudate.
  • Elements of a multi-manifold die can be: (a) similar to a monolayer die, except that there is more than one feed channel; (b) that each melt channel has its own choker bar for flow control; and/or (c) that the melt streams converge inside the die near the exit and emerge as a distinct multilayer extrudate.
  • Layer thicknesses can be determined by the design of the manifold(s) and/or die.
  • an 80/20 feed block manifold can deliver compositions in approximately a 4:1 ratio when the speed and size of each extruder is matched accordingly. This ratio can be altered by changing, for example: (a) the amount of material fed into each extruder; (b) the relative extrusion speed between one extruder and another; (c) the relative size of each extruder; and/or (d) the composition (i.e., the viscosity) of the individual layers.
  • the thickness of the overall multilayer sheet can be controlled by the overall die gap. However, the overall multilayer sheet thickness can further be adjusted, for example, by stretching (i.e., “drawing”) the melted multilayer extrudate and/or flattening the melted multilayer extrudate through a nip.
  • the multilayer structures disclosed herein can include at least 2 layers made up of different compositions, where at least one of the layers can include crosslinked, recycled polyolefin foam material (i.e., an “A” layer). In some embodiments, the multilayer structures disclosed herein can include at least one layer that is substantially free of crosslinked, recycled polyolefin foam material (i.e., a “B” layer). In some embodiments, the multilayer structure can include at least one “A” layer with crosslinked, recycled polyolefin foam material and at least one “B” layer substantially free of crosslinked, recycled polyolefin foam material. For example, the structure can be an A/B layered structure, B/A/B layered structure, B/A/C layered structure, or can have multiple other layers. In some embodiments, all layers of the multilayer structure can be foamable or foamed. The multilayer structures can include additional layers such as tie layers, film layers, and/or foam layers (including additional recycled and/or non-recycled layers) among others.
  • compositions of layers “A” and “B” fed into the extruder can include at least one polypropylene, at least one polyethylene, or a combination thereof.
  • the polypropylene may contain an elastic or softening component, typically an ethylene or rubber component and thus includes, but is not limited to, polypropylene, impact modified polypropylene, polypropylene-ethylene copolymer, impact modified polypropylene-ethylene copolymer, metallocene polypropylene, metallocene polypropylene-ethylene copolymer, metallocene polypropylene olefin block copolymer (with a controlled block sequence), polypropylene based polyolefin plastomer, polypropylene based polyolefin elasto-plastomer, polypropylene based polyolefin elastomer, polypropylene based thermoplastic polyolefin blend, and polypropylene based thermoplastic elastomeric blend.
  • the polyethylene includes, but is not limited to, LDPE, LLDPE (homopolymer, copolymer with butene or hexene or octene, terpolymer with butene and/or hexene and/or octene), VLDPE (homopolymer, copolymer with butene or hexene or octene, terpolymer with butene and/or hexene and/or octene), VLLDPE (homopolymer, copolymer with butene or hexene or octene, terpolymer with butene and/or hexene and/or octene), HDPE, polyethylene-propylene copolymer, metallocene polyethylene, metallocene ethylene-propylene copolymer, and metallocene polyethylene olefin block copolymer (with a controlled block sequence), any of which may contain cop
  • the amount of at least one polypropylene and/or at least one polyethylene in a non-recycled composition can be greater than or equal to about 50 PPHR, about 55 PPHR, about 60 PPHR, about 65 PPHR, about 70 PPHR, about 75 PPHR, about 80 PPHR, about 85 PPHR, about 90 PPHR, about 95 PPHR, or about 100 PPHR of the composition.
  • the amount of at least one polypropylene and/or at least one polyethylene in a non-recycled layer can be at least about 50 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, or about 90 wt % of the non-recycled layer.
  • the amount of at least one polypropylene and/or at least one polyethylene in a non-recycled layer can be about 50-99 wt %, about 75-97.5 wt %, about 75-95 wt %, about 80-90 wt %, or about 82-87 wt % of the non-recycled layer.
  • the compositions fed into the extruder to form the non-recycled layer(s) can be substantially free of recycled polyolefin material.
  • the compositions fed into the extruder to form the non-recycled layer(s) can also be 100 wt. % virgin or non-recycled material.
  • compositions fed into the extruders to form the recycled layer(s) can include recycled material including, but not limited to, recycled polyolefin material, recycled metallized polyolefin material, recycled polyolefin film material, recycled polyolefin metallized film material, recycled polyolefin foam material, recycled polyolefin metallized foam material, or combinations thereof.
  • the recycled crosslinked polyolefin foam material is different from the recycled crosslinked polyolefin foam material disclosed in U.S. Pat. No. 9,669,600 B2 in both how the material is prepared for recycling and the final forms.
  • FIG. 11 illustrates the difference in how the factory scrap crosslinked polyolefin foam is prepared for recycling between the two disclosures.
  • the method for recycling the crosslinked foam in the present disclosure can include four steps: shredding, agglomerating, granulating, and then either pulverizing or compounding.
  • the foam sheet can first be shredded into small pieces to facilitate feeding the foam into an agglomerator. This can be necessary since foam sheets and foam rolls—even when unwound—can typically be too wide to be pulled in or drawn into commercial agglomerators intended for foam and plastic. Shredding the foam sheet can ensure that the material will not jam or block the agglomerator. Shredding the foam sheet can also help ensure a more uniform feed rate into the agglomerator, which then can ensure uniform output from the agglomerator. Shredded foam intended for agglomeration can vary in size depending on the recommendation of the equipment manufacturer, the feed rate of the materials to be agglomerated, the melting point of the materials to be agglomerated, etc.
  • Shredded foam intended for agglomeration can generally be cut into pieces or “chips” from about 3 mm to about 20 mm wide.
  • the shredder may be a separate piece of equipment in the process or may be in-line with the agglomerator, where the shredded foam can be fed directly into the agglomerator.
  • Agglomeration can involve densifying the shredded foam.
  • Agglomerators may consist of a barrel, a conveying screw and/or rotor, and a die. As the shredded foam enters the barrel, a conveying screw and/or rotor can masticate the foam, breaking open the cells walls at the same time forming a densified material. This densification can be performed at a temperature near the melting point of the foam and the densification can be temperature controlled. A die at the back end of the barrel can form the densified material into a continuous strand as it exits the die. Depending on the system, cutting blades can then cut the strand into very course pieces to help facilitate transfer into a granulator.
  • Granulators are essentially a series of rotating and stationary knives which can cut the very course agglomerated pieces into smaller about 1-10 mm, about 2-8 mm, or about 3-7 mm granules.
  • the granules are sized so that they can be fed into typical polymer extrusion or injection molding equipment. Granulation may also be temperature controlled.
  • FIG. 3 is a photograph of the granulated 3-7 mm wide agglomerates used in producing the masterbatch which was the used to produce the multilayered foam structures of Example 2 and 3.
  • the present foam recycling process varies from U.S. Pat. No. 9,669,600 B2 in the fourth step.
  • the granules can be either a) mechanically pulverized at a temperature above cryogenic brittleness, or b) compounded into a masterbatch.
  • Mechanical pulverizers also called pulverizing mills—can further reduce the size of the granules.
  • Variously designed pulverizing mills for plastics and foams are commercially available. Thru grinding, crushing, and/or cutting, a pulverizing mill can further reduce the granules.
  • the recycled crosslinked polyolefin foam material can be pulverized down to particles from about 0.01-5 mm, about 0.1-4 mm, or 0.2-2 mm wide.
  • FIG. 2 is a photograph of mechanically pulverized, recycled crosslinked polyolefin foam used in producing Example 1 of the present disclosure.
  • Non-limiting examples of commercial systems which can shred crosslinked polyolefin foam, then agglomerate the foam, then granulate the agglomerate, and then mechanically pulverize the granules are available from Pallman Industries (Pallman Maschinenfabrik GmbH & Co. KG) and EREMA North America (EREMA Engineering Recycling Maschinen and Anlagen Ges.m.b.H.).
  • the granules can be fed into a compounding extruder along with a polyolefin carrier resin (and any of the additives disclosed herein) to produce a masterbatch. It is believed that the kneading and high temperature processing of the granules in the compounding extruder can sufficiently reduce the granules to where they can be recycled into the disclosed foams.
  • the masterbatch can be made from at least one polypropylene and/or polyethylene, the recycled granules, and/or any of the additives disclosed herein.
  • the masterbatch can be about 50-70 wt %, about 55-65 wt %, about 58-62 wt %, or about 60 wt % of at least one polypropylene and/or polyethylene. In some embodiments, the masterbatch can be about 30-50 wt %, about 35-45 wt %, about 38-42 wt %, or about 40 wt % of the recycled granules. In some embodiments, the remainder of the masterbatch can be any of the additives disclosed herein including an anti-oxidant.
  • the masterbatch used to produce Examples 2-3 in the present disclosure was produced at a specific energy of 0.32 kW-hr/kg and at an extrusion melt temperature of 419° F.
  • the amount of at least one polypropylene and/or at least one polyethylene in a recycled composition can be greater than or equal to about 50 PPHR, about 55 PPHR, about 60 PPHR, about 65 PPHR, about 70 PPHR, about 75 PPHR, about 80 PPHR, about 85 PPHR, about 90 PPHR, about 95 PPHR, or about 100 PPHR of the composition.
  • the amount of at least one polypropylene and/or at least one polyethylene in a recycled layer can be at least about 50 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, or about 90 wt % of the recycled layer. In some embodiments, the amount of at least one polypropylene and/or at least one polyethylene in a recycled layer can be about 50-99 wt %, about 75-97.5 wt %, about 75-95 wt %, about 75-90 wt %, or about 75-85 wt % of the recycled layer.
  • the amount of recycled polyolefin foam material in a recycled composition can be less than or equal to about 25 PPHR, about 20 PPHR, about 10 PPHR, about 5 PPHR, or about 2.5 PPHR of the composition. In some embodiments, the amount of the recycled polyolefin foam material in a recycled layer can be at most about 25 wt %, about 20 wt %, about 15 wt %, about 10 wt %, about 5 wt %, about 2.5 wt %, or about 2 wt % of the recycled layer.
  • the amount of the recycled polyolefin foam material in a recycled layer can be about 1-25 wt %, about 2-25 wt %, about 2.5-25 wt %, about 1-15 wt %, about 2-15 wt %, about 2-10 wt %, or about 2-9 wt % of the recycled layer.
  • compositions Since a broad range of multilayer structures and foam articles can be created with the disclosed compositions, a broad range of polypropylenes and/or polyethylenes can be employed in the compositions to meet various in-process manufacturing requirements and commercial end use requirements.
  • polypropylene is an isotactic homopolypropylene.
  • Commercially available examples include, but are not limited to, FF018F from Braskem, 3271 from Total Petrochemicals, and COPYLENETM CH020 from Conoco.
  • a non-limiting example of an “impact modified polypropylene” is a homopolypropylene with ethylene-propylene (EP) copolymer rubber.
  • the rubber can be amorphous or semicrystalline but is not in sufficient quantities to render the material any plastomeric or elastomeric properties.
  • a few non-limiting examples of commercially available “impact modified polypropylene” are TI4003F and TI4015F from Braskem and PRO-FAX® 8623 and PRO-FAX® SB786 from LyondellBasell.
  • Polypropylene-ethylene copolymer is polypropylene with random ethylene units.
  • a few non-limiting examples of commercially available “polypropylene-ethylene copolymer” are 6232, 7250FL, and Z9421 from Total Petrochemicals, 6D20 and DS6D81 from Braskem. and PRO-FAX® RP311H and ADSYLTM 7415 XCP from LyondellBasell.
  • “Impact modified polypropylene-ethylene copolymer” is polypropylene with random ethylene units and with ethylene-propylene (EP) copolymer rubber.
  • the rubber can be amorphous or semicrystalline, but is not in sufficient quantities to render the material any plastomeric or elastomeric properties.
  • a non-limiting example of a commercially available impact modified polypropylene-ethylene copolymer is PRISMA® 6910 from Braskem.
  • Metallocene polypropylene is metallocene syndiotactic homopolypropylene, metallocene atactic homopolypropylene, and metallocene isotactic homopolypropylene.
  • Non-limiting examples of “metallocene polypropylene” are those commercially available under the trade names METOCENETM from LyondellBasell and ACHIEVETM from ExxonMobil.
  • Metallocene polypropylenes are also commercially available from Total Petrochemicals and include, but are not limited to, grades M3551, M3282MZ, M7672, 1251, 1471, 1571, and 1751.
  • Metallocene polypropylene-ethylene copolymer is metallocene syndiotactic, metallocene atactic, and metallocene isotactic polypropylene with random ethylene units.
  • Commercially available examples include, but are not limited to, Lumicene® MR10MX0 and Lumicene® MR60MC2 from Total Petrochemicals and Purell® SM170G from LyondellBasell.
  • Metallocene polypropylene olefin block copolymer is a polypropylene with alternating crystallizable hard “blocks” and amorphous soft “blocks” that are not randomly distributed—that is, with a controlled block sequence.
  • An example of “metallocene polypropylene olefin block copolymer” includes, but is not limited to, the INTUNETM product line from the Dow Chemical Company.
  • Polypropylene based polyolefin plastomer POP
  • polypropylene based polyolefin elastoplastomer are both metallocene and non-metallocene propylene based copolymers with plastomeric and elastoplastomeric properties.
  • Non-limiting examples are those commercially available under the trade name VERSIFYTM (metallocene) from the Dow Chemical Company, VISTAMAXXTM (metallocene) from ExxonMobil, and KOATTROTM (non-metallocene) from LyondellBasell (a butene-1 based line of plastomeric polymers—certain grades are butene-1 homopolymer based and others are polypropylene-butene-1 copolymer based materials).
  • VERSIFYTM metalocene
  • VISTAMAXXTM metalocene
  • KOATTROTM non-metallocene
  • Polypropylene based polyolefin elastomer is both metallocene and non-metallocene propylene based copolymer with elastomeric properties.
  • propylene based polyolefin elastomers are those polymers commercially available under the trade names VERSIFYTM (metallocene) from the Dow Chemical Company and VISTAMAXXTM (metallocene) from ExxonMobil.
  • Polypropylene based thermoplastic polyolefin blend is polypropylene, polypropylene-ethylene copolymer, metallocene homopolypropylene, and metallocene polypropylene-ethylene copolymer, which have ethylene-propylene copolymer rubber in amounts great enough to give the thermoplastic polyolefin blend (TPO) plastomeric, elastoplastomeric or elastomeric properties.
  • Non-limiting examples of polypropylene based polyolefin blend polymers are those polymer blends commercially available under the trade names EXCELINKTM from JSR Corporation, THERMORUNTM and ZELASTM from Mitsubishi Chemical Corporation, ADFLEXTM and SOFTELLTM from LyondellBasell, and TELCARTM from Teknor Apex Company.
  • Polypropylene based thermoplastic elastomer blend is polypropylene, polypropylene-ethylene copolymer, metallocene homopolypropylene, and metallocene polypropylene-ethylene copolymer, which have diblock or multiblock thermoplastic rubber modifiers (SEBS, SEPS, SEEPS, SEP, SERC, CEBC, HSB and the like) in amounts great enough to give the thermoplastic elastomer blend (TPE) plastomeric, elastoplastomeric, or elastomeric properties.
  • SEBS thermoplastic rubber modifiers
  • Non-limiting examples of polypropylene based thermoplastic elastomer blend polymers are those polymer blends commercially available under the trade name GLSTM DYNAFLEXTM and GLSTM VERSAFLEXTM from Polyone Corporation, MONPRENE® from Teknor Apex Company, and DURAGRIP® from A. Schulman.
  • VLDPE and VLLDPE are very low density polyethylene and very linear density low density polyethylene containing an elastic or softening component, typically ⁇ -olefins of butene and/or hexene and/or octene.
  • an elastic or softening component typically ⁇ -olefins of butene and/or hexene and/or octene.
  • Non-limiting examples of VLDPE and VLLDPE are commercially available under the tradename FLEXOMERTM from the Dow Chemical Company and particular grades of STAMYLEXTM from Borealis.
  • Metallocene polyethylene is metallocene based polyethylene with properties ranging from non-elastic to elastomeric.
  • Non-limiting examples of metallocene polyethylene are commercially available under the trade name ENGAGETM from Dow Chemical Company, ENABLETM and EXCEEDTM from ExxonMobil, and QUEOTM from Borealis.
  • Metallocene polyethylene olefin block copolymer is a polyethylene with alternating crystallizable hard “blocks” and amorphous soft “blocks” that are not randomly distributed—that is, with a controlled block sequence.
  • An example of “metallocene polyethylene olefin block copolymer” includes, but is not limited to, the INFUSETM product line from the Dow Chemical Company.
  • polyethylenes may also be copolymers and terpolymers containing acetate and/or ester groups.
  • the comonomer groups include, but are not limited to, vinyl acetate, methyl acrylate, ethyl acrylate, butyl acrylate, glycidyl methacrylate, and acrylic acid.
  • Non-limiting examples are commercially available under the tradename BYNEL®, ELVAX® and ELVALOY® from DuPont; EVATANE®, LOTADER®, and LOTRYL® from Arkema; ESCORENETM, ESCORTM, and OPTEMATM from ExxonMobil.
  • the composition of any layer can contain at least one polypropylene having a melt flow index from about 0.1 to about 25 grams per 10 minutes at 230° C. and/or at least one polyethylene having a melt flow index from about 0.1 to about 25 grams per 10 minutes at 190° C.
  • the melt flow index of the polypropylene(s) and/or polyethylene(s) is preferably from about 0.3 to about 20 grams per 10 minutes at 230° C. and at 190° C., respectively, and more preferably from about 0.5 to about 15 grams per 10 minutes at 230° C. and at 190° C., respectively.
  • the “melt flow index” (MFI) value for a polymer is defined and measured according to ASTM D1238 at 230° C. for polypropylenes and polypropylene based materials and at 190° C. for polyethylenes and polyethylene based materials using a 2.16 kg plunger for 10 minutes. The test time may be reduced for relatively high melt flow resins.
  • the MFI can provide a measure of flow characteristics of a polymer and is an indication of the molecular weight and processability of a polymer material. If the MFI values are too high, which corresponds to a low viscosity, extrusion according to the present disclosure cannot be satisfactorily carried out. Problems associated with MFI values that are too high include low pressures during extrusion, problems setting the thickness profile, uneven cooling profile due to low melt viscosity, poor melt strength, and/or machine problems. Problems with MFI values that are too low include high pressures during melt processing, sheet quality and profile problems, and higher extrusion temperatures which cause a risk of foaming agent decomposition and activation.
  • MFI ranges are also important for foaming processes because they can reflect the viscosity of the material and the viscosity has an effect on the foaming. Without being bound by any theory, it is believed there are several reasons why particular MFI values are far more effective. A lower MFI material may improve some physical properties as the molecular chain length is greater, creating more energy needed for chains to flow when a stress is applied. Also, the longer the molecular chain (MW), the more crystal entities the chain can crystallize thus providing more strength through intermolecular ties. However, at too low an MFI, the viscosity becomes too high. On the other hand, polymers with higher MFI values have shorter chains.
  • compositions fed into the extruders may also contain additives compatible with producing the disclosed multilayered structures.
  • additives include, but are not limited to, organic peroxides, antioxidants, lubricants, thermal stabilizers, colorants, flame retardants, antistatic agents, nucleating agents, plasticizers, antimicrobials, fungicides, light stabilizers, UV absorbents, anti-blocking agents, fillers, deodorizers, odor adsorbers, thickeners, cell size stabilizers, metal deactivators, and combinations thereof.
  • the amount of additive(s) other than the chemical foaming agent(s) and the crosslinking promoter(s) in a composition can be less than or equal to about 20 PPHR, about 15 PPHR, about 10 PPHR, about 9 PPHR, about 8.5 PPHR, about 8 PPHR, about 7.5 PPHR, about 7 PPHR, about 6 PPHR, about 5 PPHR, or about 4 PPHR of the composition.
  • the amount of additive(s) other than the chemical foaming agent(s) and the crosslinking promoter(s) in a composition can be about 1-15 PPHR, about 5-10 PPHR, about 7-9 PPHR, or about 7.5-8.5 PPHR of the composition.
  • the amount of additive(s) other than the chemical foaming agent(s) and the crosslinking promoter(s) in a layer can be about 1-15 wt %, about 3-10 wt %, about 5-10 wt %, about 6-8 wt %, or about 6-7 wt % of the layer.
  • the shearing force and mixing within an extruder can be sufficient to produce a homogenous layer.
  • Co-rotating and counter-rotating twin screw extruders can provide sufficient shearing force and mixing thru the extruder barrel to extrude a layer with uniform properties.
  • Specific energy is an indicator of how much work is being applied during the extrusion of the ingredients for a layer and how intensive the extrusion process is.
  • Specific energy is defined as the energy applied to a material being processed by the extruder, normalized to a per kilogram basis. The specific energy is quantified in units of kilowatts of applied energy per total material fed in kilograms per hour. Specific energy is calculated according to the formula:
  • the extruders used to form the multilayer structures disclosed herein can be capable of producing a specific energy of at least about 0.090 kW ⁇ hr/kg, preferably at least about 0.105 kW ⁇ hr/kg, and more preferably at least about 0.120 kW ⁇ hr/kg.
  • Any layer can contain a chemical foaming agent (CFA) prior to foaming.
  • CFA chemical foaming agent
  • the extrusion temperature for any foamable layer can be at least 10° C. below the thermal decomposition initiation temperature of the chemical foaming agent. If the extrusion temperature exceeds the thermal decomposition temperature of the foaming agent, then the foaming agent will decompose, resulting in undesirable “prefoaming.”
  • the extrusion temperature for any layer can be at least 10° C. below the thermal decomposition initiation temperature of the chemical foaming agent in any foamable layer adjacent to the layer. If the extrusion temperature of the layer exceeds the thermal decomposition temperature of the foaming agent in the adjacent layer, then the foaming agent in the adjacent layer can decompose, also resulting in undesirable “prefoaming.”
  • the foam composition can include a variety of different chemical foaming agents.
  • chemical foaming agents include, but are not limited to, azo compounds, hydrazine compounds, carbazides, tetrazoles, nitroso compounds, and carbonates.
  • a chemical foaming agent may be employed alone or in any combination.
  • One chemical foaming agent that can be used in some embodiments is azodicarbonamide (ADCA).
  • ADCA's thermal decomposition typically occurs at temperatures between about 190 to 230° C. In order to prevent ADCA from thermally decomposing in the extruder, extruding temperature can be maintained at or below 190° C.
  • the amount of chemical foaming agent in a composition can be less than or equal to about 40 PPHR, about 30 PPHR, about 20 PPHR, about 15 PPHR, about 10 PPHR, or about 8 PPHR of the composition. In some embodiments, the amount of chemical foaming agent in a composition can be about 1-20 PPHR, about 2-15 PPHR, about 5-10 PPHR, or about 6-8 PPHR of the composition. In some embodiments, the amount of chemical foaming agent in a layer can be about 1-20 wt %, about 2-15 wt %, about 5-10 wt %, about 6-8 wt %, or about 6-7 wt %. The amount of chemical foaming agent can depend on the unfoamed sheet thickness, desired foam thickness, desired foam density, materials being extruded, crosslinking percentage, type of chemical foaming agent (different foaming agents can generate significantly different quantities of gas), among others.
  • a catalyst for foaming agent decomposition may be used.
  • exemplary catalysts include, but are not limited to, zinc oxide, magnesium oxide, calcium stearate, glycerin, and urea.
  • the lower temperature limit for extrusion can be that of the polymer with the highest melting point. If the extrusion temperature drops below the melting temperature of the polymer with the highest melting point, then undesirable “unmelts” appear. Upon foaming, the extruded layer that was extruded below this lower temperature limit can exhibit uneven thickness, a non-uniform cell structure, pockets of cell collapse, and other undesirable attributes.
  • Extrusion foaming can be performed with a physical foaming agent, a chemical foaming agent, or a mixture of physical and chemical.
  • Physical foaming agents can be inorganic and organic gases (nitrogen, carbon dioxide, pentane, butane, etc.) that are injected under high pressure directly into the polymer melt. The gases can nucleate and expand as the polymer melt exits the extrusion die to create the foamed polymer.
  • Chemical foaming agents can be solids that decompose exothermally or endothermally upon a decomposition temperature to produce gases. Typical gases generated from chemical foaming agents include nitrogen, carbon monoxide, carbon dioxide, ammonia, etc.
  • gases generated from chemical foaming agents include nitrogen, carbon monoxide, carbon dioxide, ammonia, etc.
  • the chemical foaming agent can be dispersed in the polymer melt and the melt heated to above the decomposition temperature of the chemical foaming agent while still in the extruder and die.
  • a foamed polymer can be made as the polymer melt exits the extrusion die.
  • typical extrusion foaming generates polymer sheets where both primary surfaces are significantly rougher than equivalent structures produced in the disclosed method.
  • the surface profile of a multilayer (as well as single layer) foam sheet can be critical in many applications and thus extrusion foamed sheets may not be used for these applications. These applications can require a smooth foam surface to obtain desired properties such as ease of lamination to a film, fabric, fiber layer, and a leather; percentage contact area in the lamination; visual aesthetics; etc.
  • U.S. Pat. No. 9,669,600 which is hereby incorporated by reference in its entirety, includes examples illustrating the difference in surface roughness between extrusion foamed polymer sheets and equivalent foamed polymer sheets produced by the disclosed method.
  • the rougher surfaces of extrusion foamed articles can be generally caused by larger sized cells (when compared to the foams produced according to the present disclosure). Although the cell size and size distribution may not be as critical in most commercial applications, because surface roughness is a function of cell size, foams with larger cells can be less desirable than foams with smaller cells for applications requiring a smooth foam surface.
  • the thickness of the unfoamed, coextruded multilayer structure can be about 0.1 to about 30 mm, about 0.2 to about 25 mm, about 0.3 to about 20 mm, or about 0.4 to about 15 mm.
  • Any individual A or B layer can have a thickness of at least about 0.05 mm, at least about 0.1 mm, at least about 0.15 mm, and at least about 0.2 mm.
  • an unfoamed recycled layer can have a thickness between about 0.5-5 mm, about 1-4 mm, about 1-2 mm, or about 1-1.5 mm.
  • an unfoamed nonrecycled layer can have a thickness between about 50-300 microns or about 100-250 microns.
  • the extruded multilayered sheet can be subjected to irradiation with ionizing radiation at a given exposure to crosslink the composition of the multilayered sheet, thereby obtaining an irradiated, crosslinked multilayer structure.
  • Ionizing radiation is often unable to produce a sufficient degree of crosslinking on polypropylene(s), polypropylene based materials, some polyethylene(s), and some polyethylene based materials.
  • a crosslinking promoter can be added to the compositions that are fed into the extruders to promote crosslinking.
  • Polymers crosslinked by ionizing radiation are commonly referred to as “physically crosslinked”.
  • chemical crosslinking the crosslinks are generated with crosslinking promoters but without the use or ionizing radiation.
  • Chemical crosslinking typically involves using either peroxides, silanes, or vinylsilanes. In peroxide crosslinking processes, the crosslinking typically occurs in the extrusion die. For silane and vinylsilane crosslinking processes, the crosslinking typically occurs post extrusion in a secondary operation where the crosslinking of the extruded material is accelerated with heat and moisture.
  • chemically crosslinked foam sheets typically exhibit primary surfaces that are significantly rougher than equivalent structures produced in the disclosed method.
  • the surface profile of a multilayer (as well as single layer) foam sheet can be critical in many applications and thus chemically crosslinked foam sheets may not be used for these applications. These applications can require a smooth foam surface to obtain desired properties such as ease of lamination to a film, fabric, fiber layer, and a leather; percentage contact area in the lamination; visual aesthetics; etc.
  • U.S. Pat. No. 9,669,600 includes examples illustrating the difference in surface roughness between chemically crosslinked foamed polymer sheets and equivalent foamed polymer sheets produced by the disclosed method.
  • the rougher surfaces of chemically crosslinked foamed articles can be generally caused by larger sized cells (when compared to the foams produced according to the present disclosure).
  • cell size and size distribution is not critical in most commercial applications, because surface roughness is a function of cell size, foams with larger cells can be less desirable than foams with smaller cells for applications requiring a smooth foam surface.
  • ionizing radiation examples include, but are not limited to, alpha, beta (electron beams), x-ray, gamma, and neutron.
  • an electron beam having uniform energy can be used to prepare the crosslinked polyolefin structure.
  • Exposure time, frequency of irradiation, and acceleration voltage upon irradiation with an electron beam can vary widely depending on the intended crosslinking degree and the thickness of the multilayered structure.
  • the ionizing radiation can generally be in the range of from about 10 to about 500 kGy, about 20 to about 300 kGy, or about 20 to about 200 kGy. If the exposure is too low, then cell stability may not be maintained upon foaming.
  • the moldability of the resulting multilayered foam structure may be poor. Moldability is a desirable property when the multilayered foam sheet is used in thermoforming applications. Also, the unfoamed sheet may be softened by exothermic heat release upon exposure to the electron beam radiation such that the structure can deform when the exposure is too high. In addition, the polymer components may also be degraded from excessive polymer chain scission.
  • the coextruded unfoamed multilayered sheet may be irradiated up to 4 separate times, preferably no more than twice, and more preferably only once. If the irradiation frequency is more than about 4 times, the polymer components may suffer degradation so that upon foaming, for example, uniform cells will not be created in the resulting foam layer(s). When the thickness of the extruded structure is greater than about 4 mm, irradiating each primary surface of the multilayered profile with an ionized radiation can be preferred to make the degree of crosslinking of the primary surface(s) and the inner layer more uniform.
  • Irradiation with an electron beam provides an advantage in that coextruded sheets having various thicknesses can be effectively crosslinked by controlling the acceleration voltage of the electrons.
  • the acceleration voltage can generally be in the range of from about 200 to about 1500 kV, about 400 to about 1200 kV, or about 600 to about 1000 kV. If the acceleration voltage is less than about 200 kV, then the radiation may not reach the inner portion of the coextruded sheets. As a result, the cells in the inner portion can be coarse and uneven on foaming. Additionally, acceleration voltage that is too low for a given thickness profile can cause arcing, resulting in “pinholes” or “tunnels” in the foamed structure. On the other hand, if the acceleration voltage is greater than about 1500 kV, then the polymers may degrade.
  • crosslinking is performed so that the composition of the extruded structure is crosslinked about 20 to about 75% or about 30 to about 60%, as measured by the “Toray Gel Fraction Percentage Method.”
  • tetralin solvent is used to dissolve non-crosslinked components in a composition.
  • the non-crosslinked material is dissolved in tetralin and the crosslinking degree is expressed as the weight percentage of crosslinked material in the entire composition.
  • the apparatus used to determine the percent of polymer crosslinking includes: 100 mesh (0.0045 inch wire diameter); Type 304 stainless steel bags; numbered wires and clips; a Miyamoto thermostatic oil bath apparatus; an analytical balance; a fume hood; a gas burner; a high temperature oven; an anti-static gun; and three 3.5 liter wide mouth stainless steel containers with lids.
  • Reagents and materials used include tetralin high molecular weight solvent, acetone, and silicone oil. Specifically, an empty wire mesh bag is weighed and the weight recorded. For each sample, 100 milligrams ⁇ 5 milligrams of sample is weighed out and transferred to the wire mesh bag.
  • the weight of the wire mesh bag and the sample is recorded.
  • Each bag is attached to the corresponding number wire and clips.
  • the bundle (bag and sample) is immersed in the solvent.
  • the samples are shaken up and down about 5 or 6 times to loosen any air bubbles and fully wet the samples.
  • the samples are attached to an agitator and agitated for three (3) hours so that the solvent can dissolve the foam.
  • the samples are then cooled in a fume hood.
  • the samples are washed by shaking up and down about 7 or 8 times in a container of primary acetone.
  • the samples are washed a second time in a second acetone wash.
  • the washed samples are washed once more in a third container of fresh acetone as above.
  • the samples are then hung in a fume hood to evaporate the acetone for about 1 to about 5 minutes.
  • the samples are then dried in a drying oven for about 1 hour at 120° C.
  • the samples are cooled for a minimum of about 15 minutes.
  • Suitable crosslinking agents include, but are not limited to, commercially available difunctional, trifunctional, tetrafunctional, pentafunctional, and higher functionality monomers. Such crosslinking monomers are available in liquid, solid, pellet, and powder forms. Examples include, but are not limited to, acrylates or methacrylates such as 1,6-hexanediol diacrylate, 1,6-hexanediol dimethacrylate, ethylene glycol diacrylate, ethylene glycol dimethacrylate, trimethylol propane trimethacrylate, tetramethylol methane triacrylate, 1,9-nonanediol dimethacrylate and 1,10-decanediol dimethacrylate; allyl esters of carboxylic acid (such as trimellitic acid triallyl ester, pyromellitic acid triallyl ester, and oxalic acid diallyl ester); allyl esters of cyanulic acid or isocyanulic acid such
  • the amount of crosslinking agent in a composition can be less than or equal to about 4 PPHR, about 3 PPHR, about 2.5 PPHR, about 2 PPHR, about 1.5 PPHR, about 1 PPHR, or about 0.5 PPHR of the composition. In some embodiments, the amount of crosslinking agent in a composition can be about 0.1-5 PPHR, about 0.5-3 PPHR, about 1-3 PPHR, or about 2-3 PPHR of the composition. In some embodiments, the amount of crosslinking agent in a layer can be about 0.5-5 wt %, about 1-3 wt %, or about 1.5-2.5 wt % of the layer.
  • crosslinking agent can be specific to DVB only. Other crosslinking agents can be more or less efficient in crosslinking than DVB. Thus, the required quantity for another crosslinking agent should be considered accordingly.
  • Crosslinking agents vary in crosslinking efficiency from, but not limited to, the ionizing radiation dosage, the polymers being crosslinked, the chemical structure of the monomer, the number of functional groups on the monomer, and whether the monomer is a liquid or a powder.
  • Crosslinks may be generated using a variety of different techniques and can be formed both intermolecularly, between different polymer molecules, and intramolecularly, between portions of a single polymer molecule.
  • Such techniques include, but are not limited to, providing crosslinking agents which are separate from a polymer chain and providing polymer chains which incorporate a crosslinking agent containing a functional group which can form a crosslink or be activated to form a crosslink.
  • foaming may be accomplished by heating the crosslinked multilayered sheet to a temperature higher than the decomposition temperature of the thermally decomposable blowing agent.
  • the foaming can be performed at about 200-260° C. or about 220-240° C. in a continuous process.
  • a continuous foaming process can be preferred over a batch process for production of a continuous foam sheet.
  • the foaming can be typically conducted by heating the crosslinked multilayered sheet with molten salt, radiant heaters, vertical or horizontal hot air oven, microwave energy, or a combination of these methods.
  • the foaming may also be conducted in an impregnation process using, for example, nitrogen in an autoclave, followed by a free foaming via molten salt, radiant heaters, vertical or horizontal hot air oven, microwave energy, or a combination of these methods.
  • the crosslinked multilayered sheet can be softened with preheating. This can help stabilize the expansion of the structure upon foaming—particularly with thick and stiff sheets.
  • the density of the multilayered foam sheet can be defined and measured using section or “overall” density, rather than a “core” density, as measured by JIS K6767.
  • the multilayered foam sheets produced using the above described method can yield foams with a section, or “overall” density of about 20-250 kg/m 3 , about 30-125 kg/m 3 , about 50-100 kg/m 3 , or about 50-80 kg/m 3 .
  • the section density can be controlled by the amount of blowing agent and the thickness of the extruded structure. If the density of the multilayered foam sheet is less than about 20 kg/m 3 , then the sheet may not foam efficiently due to a large amount of chemical blowing agent needed to attain the density.
  • the density of the sheet is less than about 20 kg/m 3 , then the expansion of the sheet during the foaming step may become increasingly difficult to control. Furthermore, if the density of the multilayered foam sheet is less than about 20 kg/m 3 , then the foam may become increasingly prone to cell collapse. Thus, it may be difficult to produce a multilayered foam sheet of uniform section density and thickness at a density less than about 20 kg/m 3 .
  • the multilayered foam sheet is not limited to a section density of about 250 kg/m 3 .
  • a foam with a section density of about 350 kg/m 3 , about 450 kg/m 3 , or about 550 kg/m 3 may also be produced.
  • the foam sheet may have a density of less than about 250 kg/m 3 since greater densities can be generally cost prohibitive when compared to other materials which can be used in a given application.
  • the foam layers produced using the above method may have closed cells.
  • at least 90% of the cells have undamaged cell walls, preferably at least 95%, and more preferably more than 98%.
  • the average cell size can be from about 0.05 to about 1.0 mm, and preferably from about 0.1 to about 0.7 mm. If the average cell size is lower than about 0.05 mm, then the density of the foam structure can typically be greater than 250 kg/m 3 . If the average cell size is larger than 1 mm, the foam may have an uneven surface. There is also a possibility of the foam structure being undesirably torn if the population of cells in the foam does not have the preferred average cell size. This can occur when the foam structure is stretched or portions of it are subjected to a secondary process.
  • the cell size in the foam layer(s) may have a bimodal distribution representing a population of cells in the core of the foam structure which are relatively round and a population of cells in the skin near the surfaces of the foam structure which are relatively flat, thin, and/or oblong.
  • the overall thickness of the foamed multilayered structure can be about 0.2 mm to about 50 mm, about 0.4 mm to about 40 mm, about 0.6 mm to about 30 mm, about 0.8 mm to about 20 mm, about 0.2-5 mm, about 0.5-3 mm, about 1-4 mm, or about 2-4 mm. If the thickness is less than about 0.2 mm, then foaming may not be efficient due to significant gas loss from the primary surface(s). If the thickness is greater than about 50 mm, expansion during the foaming step can become increasingly difficult to control. Thus, it can be increasingly more difficult to produce a multilayered structure (with recycled polyolefin foam material) with uniform section density and thickness.
  • a nonrecycled layer of the foamed, coextruded multilayer structure can have a thickness of about 1-100 microns, about 5-50 microns, about 10-30 microns, about 15-25 microns, or about 16-20 microns.
  • a recycled layer of the foamed, coextruded multilayer structure can have a thickness of about 2.7-3.3 mm.
  • the desired thickness can be obtained by a secondary process such as slicing, skiving, or bonding.
  • Slicing, skiving, or bonding can produce a thickness range of about 0.1 mm to about 100 mm.
  • a pressure sensitive adhesive layer may be disposed on at least a portion of one or both major surfaces.
  • Any pressure sensitive adhesive known in the art may be used. Examples of such pressure sensitive adhesives include, but are not limited to, acrylic polymers, polyurethanes, thermoplastic elastomers, block copolymers, polyolefins, silicones, rubber based adhesives, copolymers of ethylhexylacrylate and acrylic acid, copolymers of isooctyl acrylate and acrylic acid, blends of acrylic adhesives and rubber based adhesives as well as combinations of the foregoing.
  • the multilayer foam structures can also be thermoformed.
  • the foam can be heated to the melting point of the polyolefin blend for all the layers in the multilayer foam structure. If any layer has immiscible polymers, the multilayer foam structure may exhibit more than one melting point.
  • the multilayer foam structure can typically be thermoformed when the foam is heated to a temperature midway between the multilayer composition's lowest melting point and highest melting point.
  • the multilayer foam structure can be thermoformed onto a substrate such as a hard polypropylene, ABS, or wood fiber composite.
  • the multilayer foam structure can be thermoformed onto the substrate such that a side of a non-recycled foam layer of the multilayer foam is applied to the substrate.
  • the substrate itself can also be thermoformed at the same time as the multilayer foam structure.
  • the substrate can be applied to a side (i.e., surface) of a non-recycled foam layer of the multilayer foam.
  • a thermoformed article is an automobile air duct.
  • a closed cell foam structure can be particularly suited for this application due to its lower weight (when compared to solid plastic), its insulating properties that help maintain the temperature of the air flowing thru the duct, and its resistance to vibration (versus solid plastic).
  • a firm multilayer foam structure can be suitable for an automobile air duct.
  • the multilayer foam structures can be laminates containing the multilayer foam and a laminate layer.
  • the laminate layer can be applied to a side (i.e., surface) of a non-recycled foam layer of the multilayer foam.
  • the multilayer foam structure can, for example, be combined with a film and/or foil.
  • suitable materials for such layers include, but are not limited to, polyvinyl chloride (PVC); thermoplastic polyolefin (TPO); thermoplastic urethane (TPU); fabrics such as polyester, polypropylene, cloth and other fabrics; leather and/or fiber layers such as non-wovens.
  • PVC polyvinyl chloride
  • TPO thermoplastic polyolefin
  • TPU thermoplastic urethane
  • fabrics such as polyester, polypropylene, cloth and other fabrics
  • leather and/or fiber layers such as non-wovens.
  • Such layers may be manufactured using standard techniques that are well known to those of ordinary skill in the art.
  • the multilayer foam of the disclosure may be laminated on one or both sides with these materials and may include multiple other layers. If the multilayer foam is laminated on both sides, preferably these laminate layers can be applied to sides of non-recycled foam layers of the multilayer foam. In these laminates, a layer may be joined to an adjacent layer by means of chemical bonds, mechanical means, or combinations thereof. Adjacent laminate layers may also be affixed to each other by any other means including the use of attractive forces between materials having opposite electromagnetic charges or attractive forces present between materials which both have either a predominantly hydrophobic character or a predominantly hydrophilic character.
  • the multilayer foam structures or laminates can be used in automobile interior parts such as door panels, door rolls, door inserts, door stuffers, trunk stuffers, armrests, center consoles, seat cushions, seat backs, headrests, seat back panels, instrument panels, knee bolsters, or a headliner.
  • These multilayer foam structures or laminates can also be used in furniture (e.g., commercial, office, and residential furniture) such as chair cushions, chair backs, sofa cushions, sofa trims, recliner cushions, recliner trims, couch cushions, couch trim, sleeper cushions, or sleeper trims.
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office, and residential furniture
  • furniture e.g., commercial, office,
  • the multilayer foam laminates or structures can also be used in storage casing (e.g., commercial, office and residential) which can be either mobile or stationary. Furthermore, the multilayer foam laminates and structures can also be used in coverings such as chair cushion coverings, chair back coverings, armrest coverings, sofa coverings, sofa cushion coverings, recliner cushion coverings, recliner coverings, couch cushion coverings, couch coverings, sleeper cushion coverings, sleeper coverings, wall coverings, and architectural coverings.
  • storage casing e.g., commercial, office and residential
  • coverings such as chair cushion coverings, chair back coverings, armrest coverings, sofa coverings, sofa cushion coverings, recliner cushion coverings, recliner coverings, couch cushion coverings, couch coverings, sleeper cushion coverings, sleeper coverings, wall coverings, and architectural coverings.
  • Some embodiments include a first layer of the disclosed multilayer foam structure and a second layer selected from the group consisting of a solid hardwood floor panel, an engineered wood floor panel, a laminate floor panel, a vinyl floor tile, a ceramic floor tile, a porcelain floor tile, a stone floor tile, a quartz floor tile, a cement floor tile, and a concrete floor tile.
  • the second layer(s) can be applied to a side (i.e., surface) of the non-recycled layer(s) of the multilayer foam structure.
  • the first layer may be joined to the adjacent panel or tile by means of chemical bonds, mechanical means, or a combination thereof.
  • the adjacent laminate layers may also be affixed to each other by any other means including the use of attractive forces between materials having opposite electromagnetic charges or attractive forces present between materials which both have either a predominantly hydrophobic character or a predominantly hydrophilic character.
  • the adhesive layer can be disposed on the surface of a non-recycled layer of the multilayer foam structure. Any pressure sensitive adhesive known in the art may be used.
  • pressure sensitive adhesives examples include acrylic polymers, polyurethanes, thermoplastic elastomers, block copolymers, polyolefins, silicones, rubber based adhesives, copolymers of ethylhexylacrylate and acrylic acid, copolymers of isooctyl acrylate and acrylic acid, blends of acrylic adhesives and rubber based adhesives as well as combinations of the foregoing.
  • the foam can reduce the reflected sound pressure level when the panel is impacted, for example, when walking on the panel with boots or high heeled shoes.
  • the foam can also act as a moisture vapor barrier between the panel and sub-floor and can help provide a more uniform laydown among multiple panels since any unevenness, bumps, or spikes (for example a protruding nailhead) on the sub-floor will be buffered by the foam.
  • These floor panels and tiles can be commonly installed in residential homes, office buildings, and other commercial buildings.
  • a flooring system including: a top floor layer; a sub-floor layer; and one or more underlayment layers where at least one of the underlayment layers contains the disclosed multilayer foam structure disposed between the sub-floor and the top floor layer.
  • the sub-floor and the top floor layers can be applied to sides/surfaces of non-recycled layers of the multilayer foam structure.
  • the foam layer may or may not be joined to any adjacent layer, including the sub-floor or the top floor layer.
  • the attachment can be performed by means of chemical bonds, mechanical means, or combinations thereof.
  • the adjacent layers may also be affixed to each other by any other means including the use of attractive forces between materials having opposite electromagnetic charges or attractive forces present between materials which both have either a predominantly hydrophobic character or a predominantly hydrophilic character.
  • a popular method of attachment can be the use of either a one component urethane adhesive, a two component urethane adhesive, a one component acrylic adhesive, or a two component acrylic adhesive.
  • the adhesive can be applied during the installation of the system in residential homes, office buildings, and commercial buildings.
  • the foam in this system can serve several purposes. The foam can reduce the reflected sound pressure level when the top floor layer is impacted, for example, when walking on the panel with boots or high heeled shoes.
  • the foam can also act as a moisture vapor barrier between the panel and sub-floor and help provide a more uniform laydown among multiple panels since any unevenness, bumps, or spikes (for example a protruding nailhead) on the sub-floor will be buffered by the foam.
  • the foam can help reduce grout fracturing by buffering varying thermal expansions and contractions of the various layers in the system.
  • the disclosed structures of the present disclosure may be subjected to various secondary processes, including and not limited to, embossing, corona or plasma treatment, surface roughening, surface smoothing, perforation or microperforation, splicing, slicing, skiving, layering, bonding, and hole punching.
  • Table 3 provides the coextrusion, irradiation, and properties of the multilayer structure of Examples 1-3.
  • FIGS. 4-10 Images of the Examples at various stages of the foam structure production process can be found in FIGS. 4-10 .

Landscapes

  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Toxicology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Materials Engineering (AREA)
  • Electromagnetism (AREA)
  • General Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Plasma & Fusion (AREA)
  • General Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
US15/637,723 2017-06-29 2017-06-29 Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material Active 2038-03-31 US10501598B2 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US15/637,723 US10501598B2 (en) 2017-06-29 2017-06-29 Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material
MX2018008082A MX2018008082A (es) 2017-06-29 2018-06-28 Metodo para fabricar estructuras de espuma de poliolefina reticulada, coextruida de multiples capas a partir de material de espuma de poliolefina reticulada reciclada.
ES18180821T ES2911007T3 (es) 2017-06-29 2018-06-29 Método para fabricar estructuras de espuma de poliolefina multicapa reticulada coextruida a partir de material de espuma de poliolefina reticulada reciclada
KR1020180075424A KR102615688B1 (ko) 2017-06-29 2018-06-29 재생 가교된 폴리올레핀 발포체 재료로부터 공압출 가교된 다층 폴리올레핀 발포체 구조물을 제조하는 방법
CN201810692634.6A CN109203340A (zh) 2017-06-29 2018-06-29 由再循环交联的聚烯烃泡沫材料制备共挤出交联的多层聚烯烃泡沫结构体的方法
EP18180821.3A EP3421213B1 (en) 2017-06-29 2018-06-29 Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material
JP2018124382A JP7280669B2 (ja) 2017-06-29 2018-06-29 再循環された架橋ポリオレフィンフォーム材料からの同時押出された架橋多層ポリオレフィンフォーム構造体の製造方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15/637,723 US10501598B2 (en) 2017-06-29 2017-06-29 Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material

Publications (2)

Publication Number Publication Date
US20190002662A1 US20190002662A1 (en) 2019-01-03
US10501598B2 true US10501598B2 (en) 2019-12-10

Family

ID=62837747

Family Applications (1)

Application Number Title Priority Date Filing Date
US15/637,723 Active 2038-03-31 US10501598B2 (en) 2017-06-29 2017-06-29 Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material

Country Status (7)

Country Link
US (1) US10501598B2 (ko)
EP (1) EP3421213B1 (ko)
JP (1) JP7280669B2 (ko)
KR (1) KR102615688B1 (ko)
CN (1) CN109203340A (ko)
ES (1) ES2911007T3 (ko)
MX (1) MX2018008082A (ko)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210069948A1 (en) * 2019-09-10 2021-03-11 Ford Global Technologies, Llc Trim article having an integrated structural composition with variated densities and methods for making the same
US20230173964A1 (en) * 2021-12-02 2023-06-08 Lear Corporation Vehicle seating system and method for producing same

Families Citing this family (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9663958B2 (en) 2013-12-31 2017-05-30 Toray Plastics (America), Inc. Methods of producing foam structures from recycled metallized polyolefin material
US10384388B2 (en) 2014-12-30 2019-08-20 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same
US11007761B2 (en) 2017-03-31 2021-05-18 Toray Plastics (America), Inc. Method of making coextruded, cross-linked polyolefin foam with TPU cap layers
US11318647B2 (en) * 2018-10-29 2022-05-03 Dongguan Hailex New Material Science And Technology Co., Ltd Method of microcellular foam molding
WO2020154286A1 (en) * 2019-01-22 2020-07-30 Tredegar Surface Protection, Llc Films for use as interleaves between substrates
EP3941739A1 (en) * 2019-03-19 2022-01-26 3M Innovative Properties Company Coextruded polymeric layer
US11590677B2 (en) 2019-03-29 2023-02-28 Toray Plastics (America), Inc. Method of making coextruded, crosslinked polyolefin foam with KEE cap layers
US11590730B2 (en) 2019-03-29 2023-02-28 Toray Plastics (America), Inc. Coextruded, crosslinked polyolefin foam with KEE cap layers
LT3785873T (lt) * 2020-05-01 2022-05-10 Logoplaste Innovation Lab Lda Polimerinių medžiagų perdirbimas
KR102243438B1 (ko) * 2020-06-10 2021-04-22 김우겸 마블 문양을 형성하는 eva 발포체용 조성물 및 발포체 제조방법
CN111890655B (zh) * 2020-07-22 2021-11-23 宿迁市金田塑业有限公司 双向拉伸聚乙烯抗菌防雾薄膜的多层共挤生产工艺
WO2022060928A1 (en) * 2020-09-16 2022-03-24 Dow Global Technologies, Llc Foams manufactured using silicone-functionalized polyethylene and methods of making the same
CN112280065B (zh) * 2020-11-17 2023-03-10 中国葛洲坝集团绿园科技有限公司 一种聚乙烯再生料、其制备方法及实壁管材
WO2024078911A1 (en) * 2022-10-14 2024-04-18 Sabic Global Technologies B.V. Article comprising recycled and renewable polyethylene

Citations (73)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4203815A (en) 1978-03-14 1980-05-20 Sekisui Kagaku Kogyo Kabushiki Kaisha Process for producing crosslinked and foamed resin sheet
US4410602A (en) 1980-05-08 1983-10-18 Toyo Seikan Kaisha Ltd. Multi-layer laminated resin film
JPS59215329A (ja) 1983-05-20 1984-12-05 Sekisui Chem Co Ltd 合成樹脂架橋発泡体
US5118561A (en) 1990-10-01 1992-06-02 W. R. Grace & Co.-Conn. Recycling of barrier polystyrene foam scrap and barrier polystyrene foam containing recycled barrier polystyrene foam scrap
JPH07258445A (ja) 1994-03-25 1995-10-09 Sekisui Chem Co Ltd 架橋ポリオレフィン系樹脂発泡体の製造方法
US5462794A (en) 1990-03-16 1995-10-31 Amoco Corporation Foamed core-reclaim multi layer sheet having improved resistance to barrier film delamination
EP0679487A1 (en) 1994-04-28 1995-11-02 W.R. Grace & Co.-Conn. Multi-layer polyolefin film containing recycle polymer from cross-linked films
EP0719626A2 (en) 1994-12-27 1996-07-03 Sekisui Kaseihin Kogyo Kabushiki Kaisha Continuous manufacturing method and manufacturing apparatus of thermoplastic polyester resin foam
US5552448A (en) 1993-09-21 1996-09-03 Sekisui Chemical Co., Ltd. Plastic foam material composed of thermoplastic resin and silane-modified thermoplastic resin and method for making same
WO1996027485A1 (en) 1995-03-07 1996-09-12 W.R. Grace & Co.-Conn. Method of recycling polymer materials and sheet article made thereby
US5605961A (en) 1993-09-08 1997-02-25 Bayer Corporation Thermoplastic composition containing polyurethane and polypropylene
JPH09132661A (ja) 1995-11-08 1997-05-20 Hitachi Chem Co Ltd Ｃｍｐパッド用発泡体の製造方法
US5668217A (en) 1996-05-16 1997-09-16 Huntsman Petrochemical Corporation Amidoamine modification of polypropylene
US5721315A (en) 1993-07-13 1998-02-24 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5783630A (en) 1993-07-13 1998-07-21 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5928776A (en) 1996-11-08 1999-07-27 Jsp Corporation Composite material having polypropylene foam layer
US5959032A (en) 1993-07-13 1999-09-28 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
JPH11302425A (ja) 1998-04-21 1999-11-02 Sekisui Chem Co Ltd 流動性を有する発泡性ポリオレフィン系樹脂組成物
US5985999A (en) 1993-07-13 1999-11-16 Huntsman, Petrochemical Corporation Dyeable polyolefin containing polyetheramine modified functionalized polyolefin
JP2000037766A (ja) 1998-07-22 2000-02-08 Sekisui Chem Co Ltd オレフィン系樹脂架橋発泡体の製造方法
US6031048A (en) 1993-07-13 2000-02-29 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US6093496A (en) 1998-05-12 2000-07-25 Huntsman Petrochemical Corporation Polyolefin containing polyetheramine modified functionalized polyolefin
US6146574A (en) 1993-07-13 2000-11-14 Huntsman Petrochemical Corporation Article manufacture using polyolefin containing polyetheramine modified functionalized polyolefin
EP1066958A1 (en) 1999-07-08 2001-01-10 Cryovac, Inc. Thermoformable multi-layer partially foamed sheet
US6218023B1 (en) 1997-04-21 2001-04-17 Montell North America, Inc. Co-extruded laminate comprising at least one propylene graft copolymer layer
US6251319B1 (en) 1998-05-27 2001-06-26 The Dow Chemical Company Method of forming a thermoformable polypropylene foam sheet
US6420482B1 (en) 1993-07-13 2002-07-16 Huntsman Petrochemical Corporation Dyeable polyolefin containing polyetheramine modified functionalized polyolefin
US20020119281A1 (en) 2000-11-24 2002-08-29 Higgins Kenneth B. Textile product and method
US6586489B2 (en) 1999-04-28 2003-07-01 3M Innovative Properties Company Uniform small cell foams and a continuous process for making same
US20030219582A1 (en) 2002-05-24 2003-11-27 Sealed Air Corporation Combined sound and moisture vapor barrier sheet materials for flooring underlayment and construction applications
US20030232210A1 (en) 2002-06-18 2003-12-18 3M Innovative Properties Company Ink-receptive foam article
EP0745641B1 (en) 1994-12-14 2004-03-03 Sekisui Kagaku Kogyo Kabushiki Kaisha Thermoplastic resin foam and method of production thereof
EP1449869A1 (en) 2001-11-29 2004-08-25 Toray Industries, Inc. Crosslinked biodegradable resin continuous foamed sheet and method for production thereof
US20040229968A1 (en) 2003-05-13 2004-11-18 Narasimharao Dontula Manufacturing process for open celled microcellular foam
CN1584248A (zh) 2004-05-29 2005-02-23 青岛喜盈门应用材料有限公司 防水保温发泡卷材
US6875484B1 (en) 1999-08-09 2005-04-05 Jsp Corporation Multi-layer expansion-molded article of polypropylene resin, production process thereof, and container, shock-absorbing material for automobile and automotive member formed of the multi-layer expansion-molded article of polypropylene resin
US6949283B2 (en) 2001-12-19 2005-09-27 3M Innovative Properties Company Polymeric coextruded multilayer articles
EP1664169A1 (de) 2003-09-15 2006-06-07 BASF Aktiengesellschaft Expandierbare thermoplastische polyurethan-blends
US7083849B1 (en) 1999-06-04 2006-08-01 3M Innovative Properties Company Breathable polymer foams
CN1854126A (zh) 2004-12-08 2006-11-01 拜尔材料科学有限责任公司 制造酸官能封端固体异氰酸酯的连续方法
US20060276581A1 (en) 2003-07-22 2006-12-07 Ami Agrolinz Melamine International Gmbh Plastic products with high strength and flexibility
JP2007277417A (ja) 2006-04-07 2007-10-25 Toray Ind Inc ポリオレフィン系再生樹脂架橋発泡体およびその製造方法
US20070287003A1 (en) 2004-09-22 2007-12-13 Sekisui Plastics Co., Ltd Expanded Molded Article Having Voids
WO2009057131A2 (en) 2007-05-29 2009-05-07 Reliance Industries Limited Polyolefin composition having high melt strength
US7582352B2 (en) 2000-06-30 2009-09-01 Mitsui Chemicals, Inc. Layered product olefin foam and use
US7655296B2 (en) 2003-04-10 2010-02-02 3M Innovative Properties Company Ink-receptive foam article
CN101735763A (zh) 2010-01-05 2010-06-16 四川大学 室温固化的低粘度聚氨酯泡沫粘接剂及其制备方法
US20100215879A1 (en) 2009-02-21 2010-08-26 Dow Global Technologies Inc. Multilayer structures having annular profiles and methods and apparatus of making the same
US20100266799A1 (en) 2007-07-12 2010-10-21 Dow Global Technologies Inc. Prepolymers and polymers for elastomers
US7820282B2 (en) 2003-04-10 2010-10-26 3M Innovative Properties Company Foam security substrate
US20100286357A1 (en) 2005-12-20 2010-11-11 Mitsui Chemicals, Inc. Resin composition for toner and method for preparing resin composition for toner
US20110014835A1 (en) 2009-07-14 2011-01-20 Toray Plastics (America), Inc. Crosslinked polyolefin foam sheet with exceptional softness, haptics, moldability, thermal stability and shear strength
US7879441B2 (en) 1998-07-31 2011-02-01 3M Innovative Properties Company Articles that include a polymer foam and method for preparing same
US20110244206A1 (en) 2008-04-09 2011-10-06 Maria Cristina Penache Extruded plastic film filled with metal particles, method of production and uses thereof
US20120295086A1 (en) 2011-05-17 2012-11-22 Toray Plastics (America), Inc. Crosslinked polypropylene foam sheet for improved anchorage to tpo
CN102858859A (zh) 2010-03-29 2013-01-02 内山幸助 聚乳酸组合物、其发泡成型品和制造方法
US8404780B2 (en) 2006-11-01 2013-03-26 Dow Global Technologies Llc Articles comprising nonpolar polyolefin and polyurethane, and methods for their preparation and use
WO2013057737A2 (en) 2011-06-20 2013-04-25 Essel Propack Limited Process of recycling plastics, products and applications thereof.
US20140061967A1 (en) 2012-09-04 2014-03-06 Cpg International, Inc. Use of recycled packaging in polymer composite products
US20140070442A1 (en) 2012-09-13 2014-03-13 Jsp Corporation Method for producing multi-layer polyethylene resin foam sheet
WO2014049792A1 (ja) 2012-09-27 2014-04-03 大日本印刷株式会社 積層シート及び発泡積層シートの製造方法
CN103849004A (zh) 2014-03-06 2014-06-11 湖北祥源新材科技有限公司 一种电子辐射交联聚烯烃珠光泡棉及其制备方法
US20140170344A1 (en) 2012-12-18 2014-06-19 Spartech Corporation Multi-layer sheet structure having moisture barrier properties
US20140272380A1 (en) 2013-03-15 2014-09-18 Petoskey Plastics, Inc. Co-extruded plastic film with a foam core and a method for coating the film on a substrate
US20150174871A1 (en) 2013-12-23 2015-06-25 Henner Sollmann Coextrusion film and method of mixing
US20150183142A1 (en) 2013-12-30 2015-07-02 Toray Plastics (America), Inc. Method to direct compound extruded structure for the production of irradiation crosslinked polypropylene foam
US20150184400A1 (en) 2013-12-31 2015-07-02 Toray Plastics (America), Inc. Methods of producing foam structures from recycled metallized polyolefin material
US20160185025A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same
US20160185080A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin foam material and methods of making the same
US20160185079A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled metallized polyolefin material and methods of making the same
WO2016109544A1 (en) 2014-12-30 2016-07-07 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin material and methods of making the same
US20180281260A1 (en) 2017-03-31 2018-10-04 Toray Plastics (America), Inc. Method of making coextruded, cross-linked polyolefin foam with tpu cap layers
US20180281358A1 (en) 2017-03-31 2018-10-04 Toray Plastics (America), Inc. Coextruded, crosslinked polyolefin foam with tpu cap layers

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3738403B2 (ja) * 1996-09-12 2006-01-25 株式会社豊田中央研究所 ポリオレフィン架橋材またはポリオレフィン発泡材の再生処理方法
DE60030514T2 (de) * 1999-08-12 2007-07-05 Sumitomo Chemical Co., Ltd. Mehrschichtige geschäumte Polyolefin-Folie, Verfahren und Vorrichtung zur deren Herstellung
JP4252709B2 (ja) 2000-06-08 2009-04-08 古河電気工業株式会社 架橋ポリオレフィン発泡体の可塑化方法
CN1222401C (zh) * 2000-11-30 2005-10-12 住友化学工业株式会社 聚烯烃树脂发泡片材及其生产方法
GB2399532B (en) * 2003-03-19 2007-10-24 Econoplas Ltd Method of manufacturing drainage/irrigation elements from recycled plastics
JP2009235161A (ja) * 2008-03-26 2009-10-15 Toray Ind Inc 架橋ポリオレフィン系樹脂体の再生処理方法
CN202293102U (zh) * 2011-09-08 2012-07-04 良澔科技企业股份有限公司 架桥性聚烯烃材料再回收设备
CN103497399B (zh) * 2013-09-26 2015-08-26 浙江新恒泰新材料有限公司 一种利用发泡回料制备的聚乙烯发泡材料及其生产方法
KR102563725B1 (ko) * 2014-09-25 2023-08-07 다우 글로벌 테크놀로지스 엘엘씨 폴리올레핀계 탄성 필름 구조체, 라미네이트 및 이의 방법

Patent Citations (96)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4203815A (en) 1978-03-14 1980-05-20 Sekisui Kagaku Kogyo Kabushiki Kaisha Process for producing crosslinked and foamed resin sheet
US4410602A (en) 1980-05-08 1983-10-18 Toyo Seikan Kaisha Ltd. Multi-layer laminated resin film
JPS59215329A (ja) 1983-05-20 1984-12-05 Sekisui Chem Co Ltd 合成樹脂架橋発泡体
US5462794A (en) 1990-03-16 1995-10-31 Amoco Corporation Foamed core-reclaim multi layer sheet having improved resistance to barrier film delamination
US5118561A (en) 1990-10-01 1992-06-02 W. R. Grace & Co.-Conn. Recycling of barrier polystyrene foam scrap and barrier polystyrene foam containing recycled barrier polystyrene foam scrap
US6306964B1 (en) 1993-07-13 2001-10-23 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5959032A (en) 1993-07-13 1999-09-28 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US6465606B2 (en) 1993-07-13 2002-10-15 Huntsman Petrochemical Corporation Polyether monoamine with 36-44 EO units and 1-6 PO units
US6093773A (en) 1993-07-13 2000-07-25 Huntsman Petrochemical Corporation Polyether amine modification of polyproplene
US6420482B1 (en) 1993-07-13 2002-07-16 Huntsman Petrochemical Corporation Dyeable polyolefin containing polyetheramine modified functionalized polyolefin
US5985999A (en) 1993-07-13 1999-11-16 Huntsman, Petrochemical Corporation Dyeable polyolefin containing polyetheramine modified functionalized polyolefin
US6127480A (en) 1993-07-13 2000-10-03 Huntsman Petrochemical Corporation Dyeable polyolefin containing polyetheramine modified functionalized polyolefin
US6031048A (en) 1993-07-13 2000-02-29 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US6214914B1 (en) 1993-07-13 2001-04-10 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5965667A (en) 1993-07-13 1999-10-12 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US6146574A (en) 1993-07-13 2000-11-14 Huntsman Petrochemical Corporation Article manufacture using polyolefin containing polyetheramine modified functionalized polyolefin
US5721315A (en) 1993-07-13 1998-02-24 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5942576A (en) 1993-07-13 1999-08-24 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5783630A (en) 1993-07-13 1998-07-21 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US6140416A (en) 1993-07-13 2000-10-31 Huntsman Petrochemical Corporation Polyether amine modification of polypropylene
US5605961A (en) 1993-09-08 1997-02-25 Bayer Corporation Thermoplastic composition containing polyurethane and polypropylene
US5738922A (en) 1993-09-21 1998-04-14 Sekisui Chemical Co., Ltd. Plastic foam material composed of thermoplastic resin and silane-modified thermoplastic resin
US5646194A (en) 1993-09-21 1997-07-08 Sekisui Chemical Co., Ltd. Plastic foam material composed of thermoplastic resin and silane-modified thermoplastic resin and method for making same
US5594038A (en) 1993-09-21 1997-01-14 Sekisui Chemical Co., Ltd. Plastic foam material composed of thermoplastic resin and silane-modified thermoplastic resin and method for making same
US5552448A (en) 1993-09-21 1996-09-03 Sekisui Chemical Co., Ltd. Plastic foam material composed of thermoplastic resin and silane-modified thermoplastic resin and method for making same
JPH07258445A (ja) 1994-03-25 1995-10-09 Sekisui Chem Co Ltd 架橋ポリオレフィン系樹脂発泡体の製造方法
US5605660A (en) 1994-04-28 1997-02-25 W. R. Grace & Co.-Conn. Process for making a multi-layer film containing recycle polymer from cross-linked films
EP0679487A1 (en) 1994-04-28 1995-11-02 W.R. Grace & Co.-Conn. Multi-layer polyolefin film containing recycle polymer from cross-linked films
EP0745641B1 (en) 1994-12-14 2004-03-03 Sekisui Kagaku Kogyo Kabushiki Kaisha Thermoplastic resin foam and method of production thereof
US6537404B1 (en) 1994-12-27 2003-03-25 Sekisui Kaseihin Kogyo Kabushiki Kaisha Continuous manufacturing method and manufacturing apparatus of thermoplastic polyester resin foam
EP0719626A2 (en) 1994-12-27 1996-07-03 Sekisui Kaseihin Kogyo Kabushiki Kaisha Continuous manufacturing method and manufacturing apparatus of thermoplastic polyester resin foam
WO1996027485A1 (en) 1995-03-07 1996-09-12 W.R. Grace & Co.-Conn. Method of recycling polymer materials and sheet article made thereby
JPH09132661A (ja) 1995-11-08 1997-05-20 Hitachi Chem Co Ltd Ｃｍｐパッド用発泡体の製造方法
US5668217A (en) 1996-05-16 1997-09-16 Huntsman Petrochemical Corporation Amidoamine modification of polypropylene
US5928776A (en) 1996-11-08 1999-07-27 Jsp Corporation Composite material having polypropylene foam layer
US6218023B1 (en) 1997-04-21 2001-04-17 Montell North America, Inc. Co-extruded laminate comprising at least one propylene graft copolymer layer
JPH11302425A (ja) 1998-04-21 1999-11-02 Sekisui Chem Co Ltd 流動性を有する発泡性ポリオレフィン系樹脂組成物
US6093496A (en) 1998-05-12 2000-07-25 Huntsman Petrochemical Corporation Polyolefin containing polyetheramine modified functionalized polyolefin
US6251319B1 (en) 1998-05-27 2001-06-26 The Dow Chemical Company Method of forming a thermoformable polypropylene foam sheet
JP2000037766A (ja) 1998-07-22 2000-02-08 Sekisui Chem Co Ltd オレフィン系樹脂架橋発泡体の製造方法
US7879441B2 (en) 1998-07-31 2011-02-01 3M Innovative Properties Company Articles that include a polymer foam and method for preparing same
US6586482B2 (en) 1999-04-28 2003-07-01 3M Innovative Properties Company Uniform small cell foams and a continuous process for making same
US6586489B2 (en) 1999-04-28 2003-07-01 3M Innovative Properties Company Uniform small cell foams and a continuous process for making same
US6593380B2 (en) 1999-04-28 2003-07-15 3M Innovative Properties Company Uniform small cell foams and a continuous process for making same
US6638985B2 (en) 1999-04-28 2003-10-28 3M Innovative Properties Co. Uniform small cell foams and a continuous process for making same
US7083849B1 (en) 1999-06-04 2006-08-01 3M Innovative Properties Company Breathable polymer foams
EP1066958A1 (en) 1999-07-08 2001-01-10 Cryovac, Inc. Thermoformable multi-layer partially foamed sheet
US6875484B1 (en) 1999-08-09 2005-04-05 Jsp Corporation Multi-layer expansion-molded article of polypropylene resin, production process thereof, and container, shock-absorbing material for automobile and automotive member formed of the multi-layer expansion-molded article of polypropylene resin
US7582352B2 (en) 2000-06-30 2009-09-01 Mitsui Chemicals, Inc. Layered product olefin foam and use
US20020119281A1 (en) 2000-11-24 2002-08-29 Higgins Kenneth B. Textile product and method
EP1449869A1 (en) 2001-11-29 2004-08-25 Toray Industries, Inc. Crosslinked biodegradable resin continuous foamed sheet and method for production thereof
US6949283B2 (en) 2001-12-19 2005-09-27 3M Innovative Properties Company Polymeric coextruded multilayer articles
US20030219582A1 (en) 2002-05-24 2003-11-27 Sealed Air Corporation Combined sound and moisture vapor barrier sheet materials for flooring underlayment and construction applications
US20030232210A1 (en) 2002-06-18 2003-12-18 3M Innovative Properties Company Ink-receptive foam article
US7820282B2 (en) 2003-04-10 2010-10-26 3M Innovative Properties Company Foam security substrate
US7655296B2 (en) 2003-04-10 2010-02-02 3M Innovative Properties Company Ink-receptive foam article
US20040229968A1 (en) 2003-05-13 2004-11-18 Narasimharao Dontula Manufacturing process for open celled microcellular foam
US20060276581A1 (en) 2003-07-22 2006-12-07 Ami Agrolinz Melamine International Gmbh Plastic products with high strength and flexibility
EP1664169A1 (de) 2003-09-15 2006-06-07 BASF Aktiengesellschaft Expandierbare thermoplastische polyurethan-blends
CN1584248A (zh) 2004-05-29 2005-02-23 青岛喜盈门应用材料有限公司 防水保温发泡卷材
US20070287003A1 (en) 2004-09-22 2007-12-13 Sekisui Plastics Co., Ltd Expanded Molded Article Having Voids
CN1854126A (zh) 2004-12-08 2006-11-01 拜尔材料科学有限责任公司 制造酸官能封端固体异氰酸酯的连续方法
US20100286357A1 (en) 2005-12-20 2010-11-11 Mitsui Chemicals, Inc. Resin composition for toner and method for preparing resin composition for toner
JP2007277417A (ja) 2006-04-07 2007-10-25 Toray Ind Inc ポリオレフィン系再生樹脂架橋発泡体およびその製造方法
US8404780B2 (en) 2006-11-01 2013-03-26 Dow Global Technologies Llc Articles comprising nonpolar polyolefin and polyurethane, and methods for their preparation and use
WO2009057131A2 (en) 2007-05-29 2009-05-07 Reliance Industries Limited Polyolefin composition having high melt strength
US20100266799A1 (en) 2007-07-12 2010-10-21 Dow Global Technologies Inc. Prepolymers and polymers for elastomers
US20110244206A1 (en) 2008-04-09 2011-10-06 Maria Cristina Penache Extruded plastic film filled with metal particles, method of production and uses thereof
US20100215879A1 (en) 2009-02-21 2010-08-26 Dow Global Technologies Inc. Multilayer structures having annular profiles and methods and apparatus of making the same
US20110014835A1 (en) 2009-07-14 2011-01-20 Toray Plastics (America), Inc. Crosslinked polyolefin foam sheet with exceptional softness, haptics, moldability, thermal stability and shear strength
WO2011008845A1 (en) 2009-07-14 2011-01-20 Toray Plastics (America), Inc. Crosslinked polyolefin foam sheet with exceptional softness, haptics, moldability, thermal stability and shear strength
CN101735763A (zh) 2010-01-05 2010-06-16 四川大学 室温固化的低粘度聚氨酯泡沫粘接剂及其制备方法
CN102858859A (zh) 2010-03-29 2013-01-02 内山幸助 聚乳酸组合物、其发泡成型品和制造方法
US20120295086A1 (en) 2011-05-17 2012-11-22 Toray Plastics (America), Inc. Crosslinked polypropylene foam sheet for improved anchorage to tpo
WO2013057737A2 (en) 2011-06-20 2013-04-25 Essel Propack Limited Process of recycling plastics, products and applications thereof.
US20140061967A1 (en) 2012-09-04 2014-03-06 Cpg International, Inc. Use of recycled packaging in polymer composite products
US20140070442A1 (en) 2012-09-13 2014-03-13 Jsp Corporation Method for producing multi-layer polyethylene resin foam sheet
WO2014049792A1 (ja) 2012-09-27 2014-04-03 大日本印刷株式会社 積層シート及び発泡積層シートの製造方法
US20140170344A1 (en) 2012-12-18 2014-06-19 Spartech Corporation Multi-layer sheet structure having moisture barrier properties
US20140272380A1 (en) 2013-03-15 2014-09-18 Petoskey Plastics, Inc. Co-extruded plastic film with a foam core and a method for coating the film on a substrate
US20150174871A1 (en) 2013-12-23 2015-06-25 Henner Sollmann Coextrusion film and method of mixing
US20150183142A1 (en) 2013-12-30 2015-07-02 Toray Plastics (America), Inc. Method to direct compound extruded structure for the production of irradiation crosslinked polypropylene foam
US20180126617A1 (en) 2013-12-30 2018-05-10 Toray Plastics (America), Inc. Method to direct compound extruded structure for the production of irradiation crosslinked polypropylene foam
US9663958B2 (en) 2013-12-31 2017-05-30 Toray Plastics (America), Inc. Methods of producing foam structures from recycled metallized polyolefin material
US20150184400A1 (en) 2013-12-31 2015-07-02 Toray Plastics (America), Inc. Methods of producing foam structures from recycled metallized polyolefin material
US20170246839A1 (en) 2013-12-31 2017-08-31 Toray Plastics (America), Inc. Methods of producing foam structures from recycled metallized polyolefin material
CN103849004A (zh) 2014-03-06 2014-06-11 湖北祥源新材科技有限公司 一种电子辐射交联聚烯烃珠光泡棉及其制备方法
US20160185025A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same
WO2016109544A1 (en) 2014-12-30 2016-07-07 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin material and methods of making the same
US9669600B2 (en) 2014-12-30 2017-06-06 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin foam material and methods of making the same
US20170225431A1 (en) 2014-12-30 2017-08-10 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin foam material and methods of making the same
US20160185079A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled metallized polyolefin material and methods of making the same
US20160185080A1 (en) 2014-12-30 2016-06-30 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin foam material and methods of making the same
US20180134005A1 (en) 2014-12-30 2018-05-17 Toray Plastics (America), Inc. Coextruded, crosslinked multilayer polyolefin foam structures from recycled metallized polyolefin material and methods of making the same
US20180281260A1 (en) 2017-03-31 2018-10-04 Toray Plastics (America), Inc. Method of making coextruded, cross-linked polyolefin foam with tpu cap layers
US20180281358A1 (en) 2017-03-31 2018-10-04 Toray Plastics (America), Inc. Coextruded, crosslinked polyolefin foam with tpu cap layers

Non-Patent Citations (33)

* Cited by examiner, † Cited by third party
Title
"Modification of Polyolefins with Elastamine Polyetheramines," (Oct. 2009) technical brochure published by Huntsman Corporation; 3 pages
"The JEFFAMINE Polyetheramines," (May 2007) technical brochure published by Huntsman Corporation; 6 pages.
Baldwin et al., U.S. Appl. No. 14/144,986, filed Dec. 31, 2013; 37 pages.
Baldwin et al., U.S. Office Action dated Apr. 5, 2018, directed to U.S. Appl. No. 15/818,691; 6 pages.
Baldwin et al., U.S. Office Action dated Aug. 25, 2016, directed to U.S. Appl. No. 14/144,986; 6 pages.
Baldwin et al., U.S. Office Action dated Dec. 27, 2017, directed to U.S. Appl. No. 15/581,503; 6 pages.
Baldwin et al., U.S. Office Action dated Jan. 25, 2017, directed to U.S. Appl. No. 14/144,345; 15 pages.
Baldwin et al., U.S. Office Action dated Jun. 6, 2017, directed to U.S. Appl. No. 14/586,721; 5 pages.
Baldwin et al., U.S. Office Action dated May 17, 2018, directed to U.S. Appl. No. 14/586,781; 9 pages.
Baldwin et al., U.S. Office Action dated May 2, 2016, directed to U.S. Appl. No. 14/144,345; 18 pages.
Baldwin et al., U.S. Office Action dated Oct. 3, 2016, directed to U.S. Appl. No. 14/586,745; 8 pages.
Baldwin et al., U.S. Office Action dated Oct. 6, 2016, directed to U.S. Appl. No. 14/586,721; 7 pages.
Baldwin et al., U.S. Office Action dated Oct. 6, 2017, directed to U.S. Appl. No. 14/586,781; 8 pages.
Ben-Daat et al, Office Action dated Feb. 14, 2019, directed to U.S. Appl. No. 15/476,660; 9 pages.
Ben-Daat et al, Office Action dated Jan. 10, 2019, directed to U.S. Appl. No. 15/476,681; 14 pages.
Chinese Office Action dated Apr. 18, 2018, directed to CN Application No. 201480074773.2; 7 pages.
Chinese Office Action dated Aug. 1, 2017, directed to CN Application No. 201480074773.2; 21 pages.
European Search Report dated Sep. 14, 2018, directed to European Patent Application No. 15876173.4; 18 pages.
Extended European Search Report dated Aug. 23, 2017, directed to European Application No. 14876099.4; 9 pages.
Extended European Search Report dated Sep. 13, 2018, directed to European Application No. 18180821.3; 7 pages.
Extended European Search Report dated Sep. 4, 2018, directed to European Application No. 18164260.4; 8 pages.
Extended European Search Report dated Sep. 4, 2018, directed to European Application No. 18164262.0; 8 pages.
International Search Report and Written Opinion dated Mar. 25, 2015, directed to International Application No. PCT/US2014/72548; 10 pages.
International Search Report and Written Opinion dated May 20, 2016, directed to International Application No. PCT/US2015/67875; 14 pages.
Japanese Office Action dated Aug. 13, 2018, directed to Japanese Application No. 2016-544141; 7 pages.
Kobayashi, S. et al. (2011) "Amino-Functionalized Polyethylene for Enhancing the Adhesion between Polyolefins and Polyurethanes," Industrial & Engineering chemistry Research 50(6): 3274-3279.
Lu et al. (2003) "Promoting Adhesion to Thermoplastic Polyurethane (TPU) by Amine Functional Polypropylenes," Polymeric Materials: Science & Engineering 89: 844-847.
Lu et al. (2005) "Melt Amination of Polypropylenes," Journal of Polymer Science: Part A 43: 4217-4232.
Lu, Q. et al. (2003) "Compatibilized Blends of Thermoplastic Polyurethane (TPU) and Polypropylene," Macromolecular Sympomsia 198: 221-232.
Lu, Q. et al. (2004) "Comparing the Compatibility of Various Functionalized Polypropylenes with Thermoplastic Polyurethane (TPU)," Polymer 45: 1981-1991.
Notification of the First Office Action dated Nov. 21, 2018, directed to CN Application No. 201580071862.6; 49 pages.
Song, J. et al. (2011) "Flow Accelerates Adhesion Between Functional Polyethylene and Polyurethane," AlChE Jouma 57(12): 3496-3506.
Wang et al (2006). "Polyurethane/Polyolefin Blends: Morphology, Compatibilization and Mechanical Properties," Polymers and Polymer Composites 14 (1): 1-11.

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210069948A1 (en) * 2019-09-10 2021-03-11 Ford Global Technologies, Llc Trim article having an integrated structural composition with variated densities and methods for making the same
US11712825B2 (en) * 2019-09-10 2023-08-01 Ford Global Technologies, Llc Trim article having an integrated structural composition with variated densities and methods for making the same
US20230173964A1 (en) * 2021-12-02 2023-06-08 Lear Corporation Vehicle seating system and method for producing same
US11807143B2 (en) * 2021-12-02 2023-11-07 Lear Corporation Vehicle seating system and method for producing same

Also Published As

Publication number Publication date
EP3421213A1 (en) 2019-01-02
ES2911007T3 (es) 2022-05-17
KR20190002365A (ko) 2019-01-08
EP3421213B1 (en) 2022-01-26
JP7280669B2 (ja) 2023-05-24
MX2018008082A (es) 2019-03-14
US20190002662A1 (en) 2019-01-03
CN109203340A (zh) 2019-01-15
JP2019038992A (ja) 2019-03-14
KR102615688B1 (ko) 2023-12-18

Similar Documents

Publication Publication Date Title
EP3421213B1 (en) Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material
JP7198297B2 (ja) 再生ポリオレフィン材料からの共押出架橋多層ポリオレフィン発泡構造体及びその製造方法
US11628657B2 (en) Method of making coextruded, cross-linked polyolefin foam with TPU cap layers
US10150273B2 (en) Coextruded, crosslinked multilayer polyolefin foam structures from recycled metallized polyolefin material and methods of making the same
US10035327B2 (en) Coextruded, crosslinked multilayer polyolefin foam structures from recycled polyolefin foam material and methods of making the same
EP3385073A1 (en) Coextruded, crosslinked polyolefin foam with tpu cap layers
US10384388B2 (en) Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same
US10814590B2 (en) Methods of producing foam structures from recycled metallized polyolefin material
US11590730B2 (en) Coextruded, crosslinked polyolefin foam with KEE cap layers
US11590677B2 (en) Method of making coextruded, crosslinked polyolefin foam with KEE cap layers
WO2020205633A1 (en) Coextruded, crosslinked polyolefin foam with kee cap layers

Legal Events

Date Code Title Description
STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NOTICE OF ALLOWANCE MAILED -- APPLICATION RECEIVED IN OFFICE OF PUBLICATIONS

AS Assignment

Owner name: TORAY PLASTICS (AMERICA), INC., RHODE ISLAND

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BALDWIN, JESSE JUDE;BEN-DAAT, DAN;BISHOP, WINSTON KENNETH, III;AND OTHERS;SIGNING DATES FROM 20190705 TO 20190708;REEL/FRAME:049792/0257

STPP Information on status: patent application and granting procedure in general

Free format text: NOTICE OF ALLOWANCE MAILED -- APPLICATION RECEIVED IN OFFICE OF PUBLICATIONS

STPP Information on status: patent application and granting procedure in general

Free format text: PUBLICATIONS -- ISSUE FEE PAYMENT VERIFIED

STCF Information on status: patent grant

Free format text: PATENTED CASE

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 4TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1551); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Year of fee payment: 4